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BUREAU OF MINES 

INFORMATION CIRCULAR/1990 

3X3BS 
¥9S 




A Cobalt Commodity Recycling 
Flow Model 



By Robert C. Gabler, Jr., and William D. Riley 




YEARS g 

%U OF * X * 



U.S. BUREAU OF MINES 
1910-1990 



THE MINERALS SOURCE 



Mission: As the Nation's principal conservation 
agency, the Department of the Interior has respon- 
sibility for most of our nationally-owned public 
lands and natural and cultural resources. This 
includes fostering wise use of our land and water 
resources, protecting our fish and wildlife, pre- 
serving the environmental and cultural values of 
our national parks and historical places, and pro- 
viding for the enjoyment of life through outdoor 
recreation. The Department assessesourenergy 
and mineral resources and works to assure that 
their development is in the best interests of all 
our people. The Department also promotes the 
goals of the Take Pride in America campaign by 
encouraging stewardship and citizen responsibil- 
ity for the public lands and promoting citizen par- 
ticipation in their care. The Department also has 
a major responsibility for American Indian reser- 
vation communities and for people who live in 
Island Territories under U.S. Administration. 



Information Circular 9252 

A Cobalt Commodity Recycling 
Flow Model 



By Robert C. Gabler, Jr., and William D. Riley 



UNITED STATES DEPARTMENT OF THE INTERIOR 
Manuel Lujan, Jr., Secretary 

BUREAU OF MINES 
T S Ary, Director 






^^ 



c\ 



^ 



& 



Library of Congress Cataloging in Publication Data: 



Gabler, Robert C. 

A cobalt commodity recycling flow model / by Robert C. Gabler, Jr. and 
William D. Riley. 

p. cm. — (Bureau of Mines information circular; 9252) 

Includes bibliographical references. 

1. Cobalt industry— Mathematical models. 2. Cobalt— Recycling— Mathematical 
models. I. Riley, W. D. (William D.) II. Title. III. Series: Information circular 
(United States. Bureau of Mines); 9252. 

TN295.U4 [HD9539.C462] 622 s-dc20 [338.27483] 90-1534 
CIP 



CONTENTS 

Page 

Abstract 1 

Introduction 2 

General description 3 

Industry flow models 4 

Superalloys 4 

Magnetic alloys 5 

Cemented carbides 6 

Tool steels 6 

Stainless steels, heat-resistant steels, and other alloys 6 

Miscellaneous and unspecified uses 7 

Catalysts 7 

Other chemicals 7 

Cobalt material flows 8 

Summary 9 

Conclusions 10 

References 11 

Appendix 12 

ILLUSTRATIONS 

1. The cobalt commodity flow model 3 

2. Superalloys: wrought, cast, and composite 5 

3. Magnetic alloys: wrought, cast, and composite 6 

4. Cemented carbides 6 

5. Tool steels 6 

6. Stainless steels, heat-resistant steels, and other alloys 7 

7. Miscellaneous and unspecified products 7 

8. Catalysts 8 

9. Other chemicals 8 

10. Composite cobalt commodity flowsheet 9 

TABLES 

1. Reported and apparent consumption of cobalt in the United States, 1987 4 

2. Estimated distribution of waste and downgraded material in the superalloy industry, 1987 5 

3. Estimated distribution of waste and downgraded scrap in the magnetic alloy industry, 1987 6 

4. Estimated distribution of waste and downgraded scrap in the stainless steel, heat-resistant steel, 

and other alloys industries, 1987 7 

5. Estimated distribution of waste and downgraded scrap in miscellaneous and unspecified uses, 1987 ... 7 

6. Estimated amounts of cobalt consumed in noncatalyst chemical products, 1987 8 

7. Estimated distribution of waste and downgraded scrap in the cobalt commodity industries, 1987 8 

8. Estimated losses of cobalt in industries, 1987 10 

9. Estimated recyclable and recycled materials by industry, 1987 10 

A-l. Estimated U.S. consumption of cobalt by end use, 1987 12 



UNIT OF MEASURE ABBREVIATIONS USED IN THIS REPORT 


lb 


pound 


St 


short ton 


lb/st 


pound per short ton 


yr 


year 


pet 


percent 







A COBALT COMMODITY RECYCLING FLOW MODEL 

By Robert C. Gabler, Jr., 1 and William D. Riley 2 



ABSTRACT 

World resources of cobalt appear ample for the foreseeable future; however, political and economic 
events have caused concern over the availability and reliability of an uninterrupted supply. Because of 
this concern, the U.S. Congress requested that the U.S. Bureau of Mines initiate a study of the flow of 
cobalt in the economy that would delineate and quantify the production areas where metal values are 
lost. As a result, the Bureau has developed a computerized commodity flow model. A major attribute 
of this model is that it is amenable to updating as supply, demand, and/or production data change. This 
report follows the flow of cobalt through its metallurgical and chemical applications and highlights areas 
where significant losses occur due to downgrading, export, or disposal. The study indicates that about 
4,300,000 lb of cobalt-bearing materials are lost each year, representing 24 pet of U.S. domestic demand. 



2 Physical scientist. 

Albany Research Center, U.S. Bureau of Mines, Albany, OR. 



INTRODUCTION 



Cobalt is an indispensable element in a variety of 
critical and strategic applications such as superalloys, 
permanent magnets, cemented carbides, alloy and tool 
steels, catalysts, and chemicals. Cobalt has few viable 
substitutes in most of its major end uses. The United 
States currently is entirely dependent on foreign sources 
for its primary cobalt demands. Although world resources 
of cobalt are ample for the foreseeable future, political 
and economic events have raised doubts about the 
uninterrupted availability and reliability of supplies of 
this commodity. The largest suppliers of cobalt are the 
central Africa countries of Zaire and, to a lesser extent, 
Zambia. The risks of future disruptions from these 
sources are high (I). 3 

Various literature studies have reported the strategic 
importance of a number of commodities, their availability, 
and their vulnerability to interrupted supplies (1-8). Most 
of these studies either are out of date or do not supply 
information on losses of the strategic and critical com- 
modities due to waste disposal, downgrading, and/or 
export. 

Industry officials in the production, manufacturing, and 
recycling of strategic and critical commodities are reluctant 
to discuss the quantities of scrap that go to disposal, 
downgrading, and export. This information is often con- 
sidered to be proprietary in nature. 

Even when data are available, there is confusion 
between disposition of materials and recycling. For ex- 
ample, in a survey of seven scrap recyclers in 1987 (9), the 
following estimates were obtained for disposition of scrap 
from the superalloy industry: 

Range, pet 

Domestic recycling 60-100 

Exports 0-40 

Of recycled scrap: 

Domestic remelting 75-100 

Recycling to same superalloy 38-90 

Recycling to other high-value superalloy . 5- 38 

Downgrading 10-25 

Discarding 3- 5 

These estimates are typical of the data on processing, 
manufacturing, disposal, downgrading, and recycling of 
strategic and critical materials. Therein lies the difficulty 
in determining the amounts of critical and strategic 

Italic numbers in parentheses refer to items in the list of references 
preceding the appendix at the end of this report. 



commodities that are discarded, downgraded, or exported, 
which is the reason for conducting this study. 

In 1980, the U.S. Bureau of Mines reported the results 
of contracted studies by Inco Research and Development 
Center, Suffern, NY, and Arthur D. Little, Inc., Cam- 
bridge, MA, to assess the domestic availability of chro- 
mium in scrap and the amount that was recycled (10-11). 
These reports contain data up to 1976 and 1978, respec- 
tively; no updates of these studies were conducted follow- 
ing their publication. In 1983, the National Materials 
Advisory Board (NMAB) published a study of the flow of 
cobalt in all end uses, which discussed the amounts of 
downgraded scrap and waste produced by the cobalt in- 
dustry (1). The report also discussed the need for im- 
proved recycling of cobalt-containing scrap. 

In May 1985, the U.S. Congress, Office of Technology 
Assessment (OTA) produced a study entitled "Strategic 
Materials: Technologies To Reduce U. S. Import Vulner- 
ability" (12). Included in the study were a set of recom- 
mendations to the U.S. Bureau of Mines to conduct a 
survey of recycling-related activities. OTA recommended 
a scrap recycling study to update the chromium scrap 
metal information contained in two Bureau publications 
(10-11), as well as to expand the scope of the previous 
studies to include information on scrap generated by 
cobalt, manganese, and the platinum-group metals 
industries, as well as the wastes generated by all the 
various industrial and Department of Defense (DOD) 
users of these four commodities. 

In 1987, the Bureau initiated this study of the four com- 
modities. The main objective of the study is to produce 
a commodity-orientated structural model tracing flow, re- 
cycling, and final disposition of the four identified com- 
modities, which can be updated in subsequent years. A 
second objective of the study is to provide, in an under- 
standable manner, an overview of the commodity flow that 
can be used by Congress and industry associations as a 
tool to help in the study of that commodity's vulnerability 
to political and availability factors outside the control of 
the United States. Another objective of the study is to 
highlight significant commodity loss areas where further 
research is required. This will enable the development of 
specific project proposals to address specific recycling 
areas. 

To meet the preceding objectives of the study, a 
hierarchical model was developed for cobalt, and the data 
for cobalt are presented here. This report consists of a 
general description of the model and its components. This 
particular model is a generic model that can be applied to 
other strategic and critical commodities. 



GENERAL DESCRIPTION 



The cobalt commodity flow model is composed of a hi- 
erarchical structure and a materials balance for each 
component of the hierarchy. An overview of the 
commodity flow model is shown in figure 1. The model 
structure provides a means of organizing the overall 
industry data and of estimating material flow and waste 
generation by subcomponents of the industry. The entire 
commodity industry is represented in the first level of the 
structure, with subsequent consumers in the lower levels of 
the structure. This hierarchical structure lends itself to a 
coding system for identifying the industries and their 
relationships. The cobalt industry, for example, splits into 
eight industries at the highest level: superalloys; magnetic 
alloys; cemented carbides; 4 tool steels; stainless steels, 
heat-resistant steels, and other alloys; miscellaneous and 
unspecified industries; cobalt catalysts; and other 
chemicals. The first level of industry components would 
thus be coded: Co.l for superalloys, Co.2 for magnetic 
alloys, Co.3 for cemented carbides, etc. Under cobalt 
superalloy processing would be cobalt parts manufacturing: 
Co.1.1. A new digit is added for each descending level in 
the hierarchy. For example, the end-use industries for 
cobalt superalloys would be Co.1.1.1— jet engine turbine 
blades, Co.l.l.2-compression rings, etc. 

With adequate input data, this system permits one to 
simply, quickly, and unambiguously identify the 
subcomponents of any component of the cobalt indus- 
try. The system permits the identification of cobalt 
consumption or waste by industry component simply by 
adding all waste (or consumption) for the subcomponents. 
To list all the waste by the cobalt catalyst industry, for 
example, one simply adds the waste for all components 
whose labels start with "Co.7." If one wants to know the 
production of scrap and waste in the cobalt superalloy 
parts manufacturing industry one adds the scrap from all 
components whose labels start with "Co.1.1." 

The data organized by the hierarchical structure include 
material balances by industry. This system permits 
"upward" and "downward" calculation of consumption and 
waste quantities. That is, using this structure, one can 
distribute domestic consumption of cobalt over the 
numerous industries that consume cobalt. This is "down- 
ward" calculation. One could also start by calculating 
consumption for the lowest components and add to get 
total domestic consumption. This is "upward" calculation. 
Using both upward and downward calculation provides a 
method for checking self-consistency. Using upward and 
downward calculation also permits the estimation of limits 
on data that is not otherwise attainable. For example, if 
85 pet of the companies in an industry report data and the 



4 Cemented carbides are cutting tools and wear-resistant materials 
such as dies. 



total consumption in this industry is known, then the 
estimates of the contributions of the other 15 pet of the 
companies can be calculated by difference. 

Minimally, for the purpose of identifying scrap and 
waste generation sources, recycling routes, and potential 
recycling opportunities, each component should have a 
quantified cobalt input and output, in contained weight and 
in gross weight by material. The difference between input 
and output is identified waste. One can balance input and 
output in contained cobalt units to determine whether un- 
identified waste streams are significant 



KEY 
Waste 



CD 



Processing or 
production 



O 



Part or product 
manufacturing 

□ 

Downgraded 
scrap 

^7 

Waste 



Obsolete scrap 



Primary Co 




Cemented carbides 



■^-t 



Tool steel 




Stainless steel, 

heat-resistant steel, 

and other alloys 




Miscellaneous and 
unspecified material 



Catalyst 



^^ 



Other chemical 
Figure 1 -The cobalt commodity flow model. 



Each industry material balance is the result of material 
balances for individual processes. For example, in the pro- 
duction of superalloys, a detailed materials balance should 
be produced for each superalloy production operation. It 
is likely that each company has a different furnace, uses a 
different melting procedure, produces to different chemical 
specifications, recycles differently, and has different 
economic restrictions. All of these factors affect the 
fraction of input materials that reports to output product, 
recyclable material, or waste. It is at this level that 
information on recycling potential is most valuable. It is 
at this level that individual waste streams and scrap that 
leave the production process are identified and char- 
acterized (quantity, concentration, contamination, etc.), 
and that unidentified waste is quantified. 

With the hierarchical structure of the industry, the 
input-output materials balance for each component, and 
the detailed materials balance for each process that makes 
up an industry component, a "blueprint" for commodity 



data collection and organization has been developed. The 
base of this system is the process material balance. The 
process material balances are then aggregated to form the 
industry material balance. The industry components are 
organized by the hierarchical structure, which identifies 
material flows among industry components. 

The model developed here for the study of scrap and 
waste generated by cobalt processing and consuming in- 
dustries is a blueprint or guideline for organizing a logi- 
cal study of cobalt flow. The waste and scrap generated 
through the use of cobalt materials is identified through 
application of the material balance concept. This model 
divides the cobalt industry into smaller parts, which should 
make data collection and analysis as well as data revision 
more manageable. Problems may arise in application of 
this model; for example, some companies may be reluctant 
to provide data. But the model is general and flexible 
enough to be adapted to these problems. 



INDUSTRY FLOW MODELS 



Neither the reported consumption nor the apparent 
consumption of cobalt in any given year necessarily equals 
the actual consumption of cobalt in that year. "Reported 
consumption" is those data reported to the U.S. Bureau of 
Mines in response to the Bureau's industry consumption 
survey questionnaires. The "apparent consumption" equals 
primary production plus production from old scrap plus 
(imports minus exports) plus (beginning inventories minus 
ending inventories). Apparent consumption is closer to 
actual consumption, but reported consumption provides a 
breakdown by end use 

In developing the overall cobalt flow models, the 
following guidelines were used: 

1. The difference between reported consumption and 
apparent consumption was prorated among the various 
level 2 industry components, because there are insufficient 
data to determine where the difference belongs; 

2. It was assumed that the amount of cobalt in each of 
the level 2 industry flows that reported to loss, downgrade, 
prompt scrap, flow to manufacturing, and flow to final 
product was proportional to the 1980 data reported by 
NMAB (1) and that this proportionment is still valid at 
this time; 

3. The portions of loss and downgraded material 
for most of the metals that appear as solid scrap, mixed 
scrap, turnings, grindings, and waste were assumed to 
be proportioned as reported by Curwick, Petersen, and 
Makar (11). 

The cobalt industry comsumption data for 1987 are shown 
in table 1. 



Table 1. -Reported and apparent consumption of cobalt 

in the United States, 1987 (thousand 

pounds contained cobalt) 

Industry Reported Apparent 
Metallurgical: 

Superalloy 6,273 7,403 

Magnetic alloy 1,719 2,029 

Cutting and wear-resistant 

materials 1,174 1,386 

Tool steel 383 452 

Stainless steel, heat-resistant steel, 

and other alloys (excluding alloy 

steels and superalloys) 151 178 

Miscellaneous and unspecified 

materials 1 883 1,042 

Chemical: 

Catalyst 1,096 1,294 

Other chemical uses 2 3,422 4,040 

Total 3 15,099 17,824 

1 Full alloy steel, high-strength low-alloy steel, nonferrous alloys, 
welding materials (standard and hardfacing), and metal powder pro- 
ducts. Individual data are withheld to avoid disclosing company 
proprietary information. 

2 Driers, feed or nutritive additives, glass decolorizers, ground coat 
frit, and pigments. 

3 Data do not add to total shown because of independent rounding. 

SUPERALLOYS 

The flow of cobalt in the superalloy industry is shown 
in figure 2. Quantities were generated by the model, using 
the following assumptions: 

1. The reported amount of cobalt contained in recycled 
obsolete scrap (13) is proportioned only to superalloy and 
cemented carbides processing. 



2. The amount of cobalt from obsolete scrap used in 
cemented carbides is proportional to the ratio of obsolete 
scrap cobalt input to cemented carbides to total cobalt 
input to cemented carbides shown by NMAB (500 units of 
cobalt in obsolete scrap per 1,344 units of total cobalt 
input) (2). 

3. The input of cobalt in obsolete scrap to superalloy 
production is the difference between contained cobalt in 
total consumed obsolete scrap and contained cobalt in ob- 
solete scrap consumed in production of cemented carbides. 

4. The difference between total apparent consumption 
of cobalt in superalloy production and that part from obso- 
lete scrap is primary cobalt. 

5. The ratio of primary cobalt consumed in wrought 
products to that consumed in cast products is 2.0 (2). 

The composite flow of superalloys in the manufacture 
of parts is the sum of two independent flows, which are the 
production of wrought alloy parts and cast parts (fig. 2). 



Obsolete scrap 



Prompt scrap 




Parts (2.733) 



Wrought 



Obsolete scrap 



Prompt scrap 



(1.738) 




Parts (1.397) 



* Cast 



Obsolete scrap 



Prompt scrap 




Parts (4,130) 



* Composite 



Figure 2. -Superalloys: wrought, cast, and composite (quanti- 
ties in thousand pounds contained cobalt). Data may not add to 
totals shown because of independent rounding. 



In the superalloy industry there are two types of 
processing: In the first, metal is processed to an alloy and 
this material, in the form of a billet or ingot, then goes 
to producing a manufactured part (wrought). In the sec- 
ond, the alloy is prepared by the melting of pure metals 
by the parts manufacturer immediately prior to casting the 
parts (cast). To simplify the model, these two different 
operations are summed up as a composite flow sequence 
of superalloy processing and parts manufacturing. 

From the model, the following figures were generated. 
In 1987, the superalloy industry consumed materials esti- 
mated to contain 7,403,000 lb of cobalt, generated waste 
material estimated to contain 565,000 lb of cobalt, and 
downgraded material estimated to contain 2,707,000 lb 
of cobalt. The distribution of this material is shown in 
table 2. In many cases the loss to downgrade is due to 
the fact that specifications for certain end-use products 
require the use of virgin metal to produce the alloys. 
These requirements cause large amounts of scrap material 
to be used as a cobalt source for alloys with lower 
concentrations of cobalt and lower economic values 
(downgraded.) 

Table 2.-Estimated distribution of waste and downgraded 
material in the superalloy industry, 1987 

JO 3 //? 
Material contained Co 

Loss material: Waste 565 

Downgraded: 

Solid scrap 371 

Mixed scrap 217 

Turnings 1,089 

Grindings 1,030 

Total 3,272 



MAGNETIC ALLOYS 

The manufacture of magnets involves two major 
processes, wrought alloy processing and casting. The flows 
of cobalt in the manufacture of magnets with wrought and 
cast alloys are shown in figure 3. The composite flows of 
cobalt in all magnet manufacturing are also shown in 
figure 3. The flows were estimated based on the data of 
Curwick, Petersen, and Makar (11) and NMAB (1). An 
estimated 2,029,000 lb of cobalt was used in magnet 
manufacture in 1987. Of this amount, an estimated 
141,000 lb of cobalt reported to waste, 79,000 lb of cobalt 
to downgrade, and 1,808,000 lb of cobalt to magnets. The 
distribution of waste and downgraded materials is shown 
in table 3. NMAB states that essentially no obsolete 
cobalt magnet scrap was recycled to the production of 
cobalt-containing products (7). 



Primary Co 



(812) 



* Wrought 




Obsolete scrap 



Magnet (732) 



Primary Co 



(1,217) 



* Cast 




parts' < 1 ' 076 > 



Primary Co 



(2.029) 




Magnet 
parts 



(1,808) 



* Composite 



Figure 3.-Magnetic alloys: wrought, cast, and composite 
(quantities in thousand pounds contained cobalt). Data may not 
add to totals shown because of independent rounding. 



Table 3.- Estimated distribution of waste and downgraded 
scrap in the magnetic alloy industry, 1987 

10* lb 
contained Co 

141 

_79 

220 



Material 

Loss material, waste 

Downgraded scrap, mixed . 
Total 



CEMENTED CARBIDES 

This category consists of cutting tools and wear-resistant 
materials such as dies. The flow of cobalt in this industry 
is based on NMAB data (1) and is shown in figure 4. The 
material first goes through powder processing, where the 
only reported loss occurs. Then, the material goes to parts 
manufacturing. About 3 to 25 pet cobalt is used as a 
matrix-cement for carbide cutting tools, and about 6 to 
25 pet cobalt is used in carbide drawing dies (1). In the 
overall production of cemented carbide inserts and parts, 
obsolete scrap containing an estimated 516,000 lb of cobalt 
and 870,000 lb of primary cobalt were used, producing 
waste containing an estimated 23,000 lb of cobalt and parts 
and inserts containing an estimated 1,363,000 lb of cobalt. 




Parts (1,363) 



Figure 4.-Cemented carbides (quantities in thousand pounds 
contained cobalt). 



Primary Co 



(452) 



Semifinished 

steel 

production 



To tool mfg. 



(380) 




Tools (371) 



Figure 5.-Tool steels (quantities in thousand pounds con- 
tained cobalt). 



TOOL STEELS 

The primary use for this product is in high-speed tools. 
Cobalt is added to tungsten-chromium hot-work tool steels 
to increase the toughness and strength of the alloy at high 
temperatures (14). The flows of cobalt in this industry 
are based on NMAB data (1) and are shown in figure 5. 
In this industry an estimated 452,000 lb of cobalt is used 
to produce high-speed tools containing an estimated 
371,000 lb of cobalt. The production and manufacturing 
losses of waste are estimated to contain 81,000 lb of cobalt. 

STAINLESS STEELS, HEAT-RESISTANT STEELS, 

AND OTHER ALLOYS (EXCLUDING ALLOY 

STEELS AND SUPERALLOYS) 

The primary end use of products of this industry is in 
applications where heat and corrosion resistance are re- 
quired (75). The flows of cobalt in this industry are shown 
in figure 6. A total of 208,000 lb of contained cobalt was 
estimated to go into production of the final products. Of 
this, 178,000 lb was primary cobalt and the remainder was 
prompt scrap containing 30,000 lb of cobalt. During pro- 
duction operations, an estimated 12,000 lb of contained 
cobalt reported as waste and 39,000 lb of contained cobalt 
reported as downgraded scrap. Using the data of Curwick, 
Petersen, and Makar (11), the downgraded material is esti- 
mated to break down into solid scrap, mixed scrap, and 
grindings as shown in table 4. The final products were 
estimated to contain 128,000 lb of cobalt. NMAB reports 
that essentially no obsolete cobalt-containing scrap is used 
by this industry. 



Prompt scrap 



Primary Co 



(178) 




Final 
products 



(128) 



I 

I Home 



Figure 6.-Stainless steels, heat-resistant steels, and other 
alloys (excludes alloy steels and superalioys) (quantities in 
thousand pounds contained cobalt). Data may not add to totals 
shown because of independent rounding. 



Prompt scrap 



Primary Co 



(1.042) 




F L nal » (747) 
products 



Figure /.-Miscellaneous and unspecified products (quantities 
in thousand pounds contained cobalt). Data may not add to 
totals shown because of independent rounding. 



Table 4.-Estimated distribution of waste and downgraded 

scrap in the stainless steel, heat-resistant steel, 

and other alloys industries, 1987 



Table 5.-Estimated distribution of waste and 

downgraded scrap in miscellaneous and 

unspecified uses, 1987 



Material 

Loss material: 

Grindings 

Waste 

Downgraded: 

Solid scrap 

Mixed scrap 

Grindings 

Total 



10 3 lb 
contained Co 



1 
11 



28 

8 

_3 

51 



MISCELLANEOUS AND UNSPECIFIED USES 

This series of end-use industries produces the following 
products: welding materials for structural and hardfacing 
applications, high-strength low-alloy steels, full alloy steels, 
nonferrous alloys, mill products made from metal powder, 
and other unspecified uses. Individual data are withheld 
by the Bureau to avoid disclosing company proprietary 
data. Information in the 1979 to 1984 Minerals Year- 
books (16) indicates that an average of 82 pet of the cur- 
rently designated miscellaneous and unspecified materials 
were known to be metal alloys. Thus, a metallurgical flow 
model used by NMAB (7) was used as a blueprint for this 
portion of the cobalt industry. The data are shown in fig- 
ure 7. NMAB states that essentially no obsolete cobalt- 
containing scrap is used to produce these products (7). 
An estimated 1,042,000 lb of primary cobalt was used by 
these industries in 1987. From this input, the processing 
and manufacturing parts of the industries were estimated 
to produce final products containing 747,000 lb of cobalt. 
During the processing and manufacturing operations, waste 
material containing 69,000 lb of cobalt and downgraded 
scrap containing 227,000 lb of cobalt were generated. 
Estimates, based on the data of Curwick, Petersen, and 
Makar (11), show that the downgraded scrap can be 
broken down into solids, mixed scrap, and grindings as 
shown in table 5. 



Material 

Loss material: 

Grindings 

Waste 

Downgraded: 

Solid scrap 

Mixed scrap 

Grindings 

Total 



10 3 lb 
contained Co 



7 
63 

162 
45 
20 

297 



CATALYSTS 

A major use of cobalt in chemical products is as cata- 
lysts. The catalysts are used for hydrogenation, hydration, 
desulfurization, oxidation, reduction, and synthesis of hy- 
drocarbons (14-16). The flows of cobalt in the catalyst 
industry are shown in figure 8. The amounts in the flow- 
chart are estimated using data from NMAB (1). In 1987, 
an input of materials containing an estimated 1,294,000 lb 
of cobalt produced catalysts containing an estimated 
1,218,000 lb of cobalt. Process and manufacturing waste 
materials contained an estimated 76,000 lb of cobalt. 
Some of these catalysts can be regenerated several times, 
but ultimately the fate of most is disposal or metal 
recovery. The Bureau has developed technology to recover 
cobalt from the spent catalysts (17), and there is currently 
some reported use of recycling technology by industry. 
Deering reports that between 500,000 and 1,000,000 lb of 
cobalt is recovered from spent catalysts annually (18) . 
This recycling activity would lead to an estimated disposal 
of spent catalysts containing in the range of 218,000 to 
718,000 lb of cobalt per year. 

OTHER CHEMICALS 

This industry produces chemicals in the form of paint 
driers for lacquers, enamels and varnishes; feed additives; 




Catalysts (1,218) 



Figure 8.-Catalysts (quantities in thousand pounds contained 
cobalt). 




products 



(3.723) 



Figure 9.-Other chemicals (quantities in thousand pounds 
contained cobalt). 



decolorizers for soda-lime-silicate glasses; ground glass 
frits to improve the adherence of porcelain enamels to 
sheet metal; pigments in colors of violet, blue, green, and 
pink; and salts (14). The flows of cobalt in this industry 
are shown in figure 9. Chemical processing efficiency is 
about 97 pet, and chemical manufacturing efficiency is 
somewhat lower, about 95 pet (1). These values were used 
in defining flows within this industry. The model estimates 
that the industry used about 4,040,000 lb of primary co- 
balt in 1987. This reports as waste material contain- 
ing 317,000 lb of cobalt and final products containing 
3,723,000 lb of cobalt. The model's estimated distribution 
of cobalt among these products based on reported con- 
sumption is shown in table 6. About two-thirds of the 
products are paint driers. 

Table 6. - Estimated amounts of cobalt consumed in 
noncatalyst chemical products, 1987 



Product 

Paint driers 

Ground coat frit 

Pigments 

Feed additives 

Glass decolorizers 

Total 



10 3 lb 
contained Co 

2,141 

863 

620 

58 

41^ 

3,723 



COBALT MATERIAL FLOWS 

The overall flows of cobalt in the industries using co- 
balt are shown in figure 10. In the chemical portion of 
the flowchart, in 1987, the industries consumed an esti- 
mated 5,334,000 lb of cobalt. During processing and man- 
ufacturing operations, materials containing an estimated 
393,000 lb of cobalt were lost as waste. The final products 
contain an estimated 4,941,000 lb of cobalt. Approximately 
two-thirds of this material is used in dissipative end uses 
where recovery and recycling do not occur. Some metal 
recovery from catalysts has been reported by Deering (18). 
In the metallurgical portion of the flowchart, in 1987, the 
industries consumed obsolete scrap containing an esti- 
mated 2,510,000 lb of cobalt, an estimated 9,980,000 lb of 
primary cobalt, and prompt scrap containing an estimated 
2,243,000 lb of cobalt. During processing and manufactur- 
ing, materials containing an estimated 893,000 lb of cobalt 
were lost as waste, and scrap materials containing an esti- 
mated 3,052,000 lb of cobalt were downgraded with signifi- 
cant loss of cobalt values. The final products contain an 
estimated 8,547,000 lb of cobalt. Based on prior studies of 
the content of waste and downgraded scrap streams (10), 
the waste and downgraded scrap streams are divided as 
shown in table 7. These losses and downgrades caused the 
resource loss of about 24 pet of the 1987 apparent con- 
sumption of cobalt; the downgraded scrap is either melted 
to other alloys in which the cobalt may be lost or greatly 
diluted, or exported for refining to recover nickel and 
cobalt. There is much uncertainty about the portion of 
the downgraded and obsolete scrap that goes to export. 
The U.S. Bureau of Mines reported that 403,000 lb of 
contained cobalt was exported in 1987 (13). This includes 
cast cobalt materials, cobalt alloys, waste, and scrap. 
Estimates from Bureau of Census data for 1987 reported 
by the U.S. Bureau of Mines indicate the contained cobalt 
exported to be about 806,000 lb (19). There do not appear 
to be valid figures for the amounts from wastes and scrap 
in these estimates. 

Table 7.-Estimated distribution of waste and downgraded 
scrap in the cobalt commodity industries, 1987 

TO 3 to 
Material contained Co 

Loss material: 

Grindings 8 

Waste 1,276 

Downgraded: 

Solid scrap 564 

Mixed scrap 347 

Turnings 1,092 

Grindings 1,049 

Total 4,336 



Obsolete scrap 



Prompt scrap 



Apparent 
consumption 



(17,824) 



(2,510) 

Primary Co 




(2,243) 



Primary Co 



(15.314) 



(9,980) 



Metallurgical 
processing 



To mfg. 



Home 



scrap 




(13,527) 



Downgraded 

scrap 

(3,052) 




Products 

and (8,547) 
parts 



Primary Co 



(5,334) 



Chemical 



processing 
\ / 



To mfg. 



(5,175) 





Final 
products 



(4,941) 



Figure 10.-Composite cobalt commodity flowsheet (quantities in thousand pounds contained cobalt), 
shown because of independent rounding. 



Data may not add to totals 



SUMMARY 



A Bureau commodity flow model was updated and 
computerized for the industries that consume cobalt. 
Based on available data, the flow model follows cobalt 
through its processing and manufacturing industries 
showing estimated values for material lost through 
disposal, downgrading, and dissipation. The model was 
prepared using certain estimates and assumptions. The 
model has the capability of easy updating as new data 
become available. 

An industry flowchart was presented for each of the 
industries that consume cobalt. The flow of the entire 
cobalt commodity was also described based on the flows in 
the individual industries (fig. 10). The apparent con- 
sumption of cobalt in 1987 was 17,824,000 lb. The esti- 
mated amounts consumed by the various industries were 
shown in table 1. The largest consumer was the superalloy 
industry, which used material containing 7,403,000 lb of 
cobalt in its operations. This was estimated to be 
composed of obsolete scrap containing 1,994,000 lb of 
cobalt and 5,409,000 lb of primary cobalt. This industry 
was also the largest producer of downgraded scrap 
and wastes, producing downgraded scrap containing 
2,707,000 lb of cobalt and waste containing 565,000 lb of 
cobalt (table 8). Other high losses of cobalt occurred in 
the chemical industries and in the miscellaneous and 



unspecified areas. Over all, downgraded scrap material 
containing an estimated 3,052,000 lb of cobalt and waste 
material containing an estimated 1,284,000 lb of cobalt 
were produced. In addition to these amounts, an esti- 
mated 3,290,000 lb of cobalt is consumed in dissipative 
chemical and catalyst end uses. 

Based on the estimated lifetimes of various metal pro- 
ducts (2) and the estimated amounts of products produced 
in 1977 (10 years), 1982 (5 years), and 1985 (2 years), in 
1987 there should have been potentially recyclable metal 
products containing 8,432,000 lb of cobalt. Table 9 shows 
the distribution of these products, their potential life span, 
the amount of cobalt content potentially recyclable, and 
the amount estimated to have been recycled to the same 
alloy without downgrading. About 83 pet of obsolete 
superalloy scrap and 52 pet of the obsolete cemented 
carbide scrap is estimated to be recycled. Overall, only an 
estimated 30 pet of the total obsolete scrap was efficient- 
ly recycled. Assumptions are that essentially no obsolete 
scrap is effectively recycled from magnets, tool steels, 
stainless and heat-resistant steels, and miscellaneous 
and unspecified material. Thus, there is an estimated 
5,922,000 lb of contained cobalt in the obsolete scrap that 
is not recycled to the same or equal-value alloy. 



10 



Table 8.-Estimated losses of cobalt in industries, 1987 



Loss 



Industry 



Operation 



10 3 lb 


pet of 


contained 


U.S. 


Co 


consumption 


2,234 


12.5 


473 


2.7 


356 


2.0 


209 


1.2 


196 


1.1 


175 


1.0 


121 


.7 


79 


.4 


79 


.4 


72 


.4 


62 


.3 


52 


.3 


52 


.3 


38 


.2 


38 


.2 


30 


.2 


23 


.1 


17 


.1 



Superalloy 

Do 

Do 

Do 

Other chemical . . . 
Miscellaneous and 
unspecified. 
Other chemical . . . 
Magnetic alloy 

Do 

Tool steel 

Magnetic alloy 
Miscellaneous and 
unspecified. 

Do 

Catalyst 

Do 

Stainless steel, 
heat-resistant steel, 
and other alloy. 
Cemented carbide . 
Miscellaneous and 
unspecified. 
Stainless steel, 
heat-resistant steel, 
and other alloy. 

Do 

Tool steel 

Stainless steel, 
heat-resistant steel, 
and other alloys. 



Manufacturing downgrade 
Processing downgrade . . 

Processing waste 

Manufacturing waste .... 

. . do 

Manufacturing downgrade 

Processing waste 

Processing downgrade . . 

Processing waste 

. . do 

Manufacturing waste .... 
Processing downgrade . . 

Processing waste 

Manufacturing waste .... 

Processing waste 

Manufacturing downgrade 

Processing waste 

Manufacturing waste .... 

Processing downgrade . . 

Processing waste 

Manufacturing waste .... 
. . do 



.05 



.05 
.05 
.02 



Table 9. - Estimated recyclable and recycled materials by 
industry, 1987, thousand pounds contained cobalt 



Product 



Lifetime, 

yr 1 



Potentially 
recyclable 



Estimated 
recycle 



Superalloys 

Magnetic alloys 

Cemented carbides 

Tool steels 

Stainless steel, heat-resistant steel, and other 
alloys (excluding alloys steels and superalloys) 

Miscellaneous and unspecified 

Total 

'Reference 1, page 24. 



10 


2,400 


1,994 


10 


4,200 





2 


1,000 


516 


5 


100 





5 


100 





5 


600 






8,400 



2,510 



CONCLUSIONS 



A cobalt commodity flow model has been developed. 
The model is set up in a hierarchical manner with levels 
for the various industries and subindustries. The mathe- 
matical relationships in the model are discussed in the 
appendix. The model shows the distribution of apparent 
1987 consumption of 17,824,000 lb of cobalt in eight 
subindustries. Estimates in table 8 show production of 
downgraded scrap containing 3,052,000 lb cobalt and loss 
or waste material containing 1,284,000 lb cobalt. The 
largest producer of scrap and waste is the superalloy 
industry, in which scrap and waste produced during alloy 
processing and parts manufacturing contain 5,311,000 lb of 



cobalt. Of this, 2,039,000 lb of contained cobalt was in 
prompt scrap that was reused by the industry. The re- 
maining material containing 3,271,000 lb cobalt is divided 
into downgraded scrap with 2,707,000 lb of cobalt and 
waste with 565,000 lb of cobalt. These two loss areas are 
places where prime concern should be addressed in studies 
of recycling. The principal cause of the downgrading of 
materials is that certain end uses require virgin metal, and 
thus, any scrap is downgraded to production of lower value 
alloys or alloys where the cobalt is lost in processing. 

The development of this flow model has highlighted 
areas where data are needed to make the model more 



11 



effective. There are few or no current data available on 
the amounts of material that report as solid scrap, mixed 
scrap, turnings, grindings, and waste. The amounts calcu- 
lated in this model are based on data from 1980 and 1976. 
In the past outside contractors have gathered these data 
(i, 10). The Bureau needs to make changes in its data 



gathering survey sheets to obtain the required information 
on a continuing basis so that this model can be kept up to 
date. There are some Environmental Protection Agency 
data that are useful in determining the amounts of waste 
and downgraded material, but even these data have 
substantial gaps. 



REFERENCES 



1. National Materials Advisory Board-National Research Council. 
Cobalt Conservation Through Technological Alternatives. (BuMines 
contract J0113103). Nat. Acad. Press, Publ. NMAB^t06, 1983, 204 pp. 

2. Peterson, G. R, D. I. Bleiwas, and P. R Thomas. Cobalt 
Availability-Domestic. A Minerals Availability System Appraisal. 
BuMines IC 8848, 1981, 31 pp. 

3. Mishra, C. P., C. D. Sheng-Fogg, R G. Christiansen, 
J. F. Lemons, Jr., and D. L. De Giacomo. Cobalt Availability-Market 
Economy Countries. A Minerals Availability Program Appraisal. 
BuMines IC 9012, 1985, 33 pp. 

4. U.S. Department of Commerce. Critical Materials Requirements 
of the U.S. Steel Industry. U.S. GPO, 1983, 259 pp. 

5. National Materials Advisory Board-National Research Council. 
Basic and Strategic Metals Industries: Threats and Opportunities. Nat. 
Acad. Press, Publ. NMAB-425, 1985, 151 pp. 

6. Kilgore, C. C, and P. R Thomas. Manganese Availability- 
Domestic. A Minerals Availability System Appraisal. BuMines 
IC 8889, 1982, 14 pp. 

7. Anstett, T. F., D. I. Bleiwas, and C. Sheng-Fogg. Platinum 
Availability-Market Economy Countries. A Minerals Availability 
System Appraisal. BuMines IC 8897, 1982, 16 pp. 

8. U.S. Bureau of Mines. An Appraisal of Minerals Availability for 
34 Commodities. B 692, 1987, 300 pp. 

9. Papp, J. F. Letter report (USAF Mil. Interdep. Purchase Request 
FY615-87-05292), July 29, 1987, 19 pp. Available upon request from 
R C. Gabler, Jr., BuMines, Albany, OR 

10. Kusik, C. L, H. V. Makar, and M. R Mounier. Availability of 
Critical Scrap Metals Containing Chromium in the United States. 



Wrought Stainless Steels and Heat-Resisting Alloys. BuMines IC 8822, 
1980, 51 pp. 

11. Curwick, L. R, W. A. Petersen, and H. V. Makar. Availability of 
Critical Scrap Metals Containing Chromium in the United States. 
Superalloys and Cast Heat- and Corrosion-Resistant Alloys. BuMines 
IC 8821, 1980, 51 pp. 

12. U.S. Congress, Office of Technology Assessment. Strategic 
Materials: Technologies To Reduce U.S. Import Vulnerability. 
OTA-rTE-248, 1985, 409 pp. 

13. U.S. Bureau of Mines. Minerals and Materials. A Bimonthly 
Survey. Oct./Nov. 1988, 59 pp. 

14. Planinsek, F., and J. B. Newkirk. Cobalt and Cobalt Alloys. Ch. 
in Kirk-Othmer Encyclopedia of Chemical Technology. Wiley, 3d ed., 
v. 6, 1979, pp. 481-494. 

15. Kirk, W. S. Cobalt. Ch. in Mineral Facts and Problems, 
1985 Edition. BuMines B 675, 1985, pp. 171-183. 

16. U.S. Bureau of Mines. Minerals Yearbooks 1978-86. Chapter on 
Cobalt. 

17. Siemens, R E., B. W. Jong, and J. H. Russell. Potential of Spent 
Catalysts as a Source of Critical Metals. Conserv. & Recycl., v. 9, No. 
2, 1986, pp. 189-196. 

18. Deering, W. Presentation on catalyst recycling. Pres. at the 
Metals Week Ni-Mo-Co Conference, Tucson, AZ, Oct. 26-28, 1988, 
8 pp.; available from R C. Gabler, Jr., BuMines, Albany, OR 

19. Kirk, W. S. Cobalt. Ch. in BuMines Minerals Yearbook 1987, 
v. 1, pp. 271-278. 



12 



APPENDIX 



This section discusses the assumptions and mathematics Obsolete scrap used in superalloy production was 

used in developing the cobalt commodity flow model. The determined as follows: 
assumptions for overall cobalt data are- 

1. Assume that the reported ratio of input obsolete 

1. The difference between reported consumption and scrap to total input cobalt consumed in cemented carbide 
apparent consumption is proportionally divided among the products production in 1980 is still valid (i). 
components of "U.S. consumption of cobalt by end use" 2. Assume that obsolete scrap is recycled only to 
(table A- 1). The data under "apparent consumption" were superalloy and cemented carbide products (i). 

used in the flow model. 

2. The ratios of wastes and downgraded scrap materials Then A = B x C, (A-l) 
reported by NMAB (i) 1 are still valid until new data are 

available. where A = total cobalt in obsolete scrap input to 

SUPERALLOYS cobalt flow, thousand pounds con- 
tained cobalt, 

Superalloy operations are carried out in two processes, 

superalloy production and parts manufacturing. In the B = total cobalt input in obsolete scrap, st, 
casting industry the two steps are sometimes carried out by 

the same company, which melts primary metals to form and C = (2,000 Ib/st cobalt)/l,000. 
the alloy and then casts it into near-net-shape parts. These 

are then machined to final dimensions. For simplicity Then D = A x E, (A-2) 
these operations are described as superalloy production 

and parts manufacturing in the flow model for both types where D = obsolete scrap input to cemented 

of operations. carbide, thousand pound contained 

The value for cobalt consumption for superalloys from cobalt, 
table A-l was used for input cobalt (not including prompt 

scrap) (19). and E = ratio of cobalt input from obsolete scrap 
to cemented carbide products to total 

'italic numbers in parentheses refer to items in the list of references cobalt consumed in cemented carbide 

preceding this appendix. products in 1980 (i). 

Table A-1 .-Estimated U.S. consumption of cobalt by end use, 
1987 (thousand pounds of contained cobalt) 

End use Reported (78) Apparent 

Superalloys 2 6,273 7,403 

Alloys (excluding alloy steels and superalloys): 

Magnetic 1,719 2,029 

Cutting and wear-resistant 3 1,174 1,386 

Nonferrous W W 

Welding materials (structural and hardfacing) W W 

Other 94 111 

Steels: 

Tool 383 452 

Stainless and heat-resisting 57 67 

Full-alloy W W 

High-strength low-alloy W W 

Mill products made from metal powder W W 

Miscellaneous and unspecified 883 1,042 

Chemical and ceramic uses: 

Driers in paint and related products 1,968 2,323 

Catalysts 1,096 1,294 

Ground coat frit 794 937 

Pigments 570 673 

Feed and nutritive additives 53 63 

Glass decolorizers 37 44 

Total 4 1 5,099 17,824 

W Withheld to avoid disclosing company proprietary data; included with "Miscellaneous and unspecified." 
'U.S. primary + secondary production + imports -exports + adjustments for Government and industry stock 

changes. 

2 Data not comparable to those prior to 1986 because of the addition of statistical canvass coverage of the 

superalloy recycling industry. 

3 Cemented and sintered carbides and cast carbide dies and parts. 
"Data do not add to total shown because of independent rounding. 



13 



Then 
where 

Then 
where 

and 



F = A - D, 



(A-3) 



= obsolete scrap input to superalloy pro- 
duction. 



G = H - F, 



(A-4) 



H 



= primary cobalt input to superalloy pro- 
duction, 

= cobalt input to superalloy production 
from obsolete scrap and primary co- 
balt (19). 



Then 

where I 



I = (F + G) x 0.2754, 



(A-5) 



= prompt scrap input to superalloy pro- 
duction, 



and 0.2754 = ratio of cobalt input to superalloy pro- 
duction from prompt scrap to sum of 
primary cobalt and obsolete scrap (1). 

Then J = sum(F + G + I) x 0.31/8.15, (A-6) 

where J = superalloy processing waste, 

and 0.31/8.15 = ratio of superalloy processing waste to 
total cobalt input (1). 

Then K = sum(F + G + I) x 0.41/8.15, (A-7) 

where K = superalloy processing downgraded 

scrap, 

and 0.41/8.15 = ratio of superalloy processing down- 
graded scrap to total cobalt in- 
put (1). 



Then L 

where L 
Then 

where M 
and 0.18/7.43 

Then 

where N 



= sum(F + G + I) - J - K, (A-8) 

= input to superalloy parts manufacturing. 

M = L x 0.18/7.43, (A-9) 

= superalloy parts manufacturing waste, 

= ratio of superalloy manufacturing waste 
to cobalt input to superalloy parts 
manufacturing (/). 



N = L x 1.92/7.43, 



(A-10) 



= superalloy parts manufacturing down- 
graded scrap, 



and 1.92/7.43 = ratio of superalloy manufacturing 
downgraded scrap to cobalt input to 
superalloy parts manufacturing (1). 

Then P = L - M - N - I, (A-ll) 

where P = superalloy manufactured parts. 

Then Q = sum(F + G + I) x 0.8/8.15, (A-12) 

where Q = estimated superalloy downgraded scrap 

and waste exported, 

and 0.08/8.15 = ratio of exported material to superalloy 
total input (1). 

MAGNETIC ALLOYS 

Magnetic alloy operations are carried out in two basic 
phases, alloy production and parts manufacturing. 



S = R x 0.09/2.3, 



(A-13) 



where 



R = primary cobalt input to magnetic al- 
loys (19), 

S = magnetic alloy processing waste, 



and 0.09/2.3 = ratio of magnetic alloy processing waste 
to cobalt input to magnetic alloys (1). 



Then 
where 



T = R x 0.09/2.3, 



(A-14) 



T = magnetic alloy processing downgraded 
waste, 



and 0.09/2.3 = ratio of magnetic alloy processing 
downgraded scrap to cobalt input to 
magnetic alloys (1). 



Then 




U = R - S - T, (A-15) 


where 


U 


= magnetic alloy input to parts manufac- 
turing. 


Then 




V = U x 0.07/2.12, (A-16) 


where 


V 


= magnetic alloy parts manufacturing 
waste, 



and 0.07/2.12 = ratio of magnetic alloy parts manufac- 
turing waste to cobalt input to magnet- 
ic alloy parts manufacturing (1). 



14 



Then W = U - V, (A-17) 

where W = magnetic alloy parts and products. 

CEMENTED CARBIDE MATERIALS 

This industry, which makes cemented carbide cutting 
tools and cast wear resistant dies, is a two-stage operation. 
Stage 1 is the processing of carbide materials and stage 2 
is the manufacturing of parts and products. This is the 
other one of two industries that use significant amounts of 
obsolete scrap in their processing and manufacturing. 



Y = X x 0.50/1.30, 



(A-18) 



where X = total cobalt input to manufacture of 

cemented carbide, 

Y = obsolete scrap input, 

and 0.50/1.30 = ratio of cobalt input from obsolete 
scrap to total cobalt input to this 
industry (1). 



Then 



Z = X - Y. 



(A-19) 



where Z = primary cobalt input to manufacture 

and production of cemented carbide 
products. 

Then AA = Xx 0.03/1.8, (A-20) 

where AA = cemented carbide processing waste, 

and 0.03/1.8 = ratio of cemented carbide processing 
waste to total cobalt input (1). 



Then 



BB = X - AA, 



(A-21) 



where BB = input to cemented carbide products 
manufacturing. 



Then 



CC = BB x 0.03, 



(A-22) 



where CC = cemented carbide products manufac- 
turing waste, 

and 0.03 = waste fraction based on an estimated 

97-pct efficiency in manufacturing 
cemented carbide products (1). 

Then DD = BB - CC, (A-23) 

where DD = cemented carbide products. 



TOOL STEELS 

This industry consists of operations to produce tool 
steels and the manufacturing of parts from the tool steel. 



FF = EE x 0.08/0.5, 



(A-24) 



where EE = primary cobalt input for production of 
tool steels (79), 

FF = tool steel production waste, 

and 0.08/0.5 = ratio of tool steel production waste to 
primary cobalt input (1). 



Then 



GG = EE - FF, 



(A-25) 



where GG = tool steel input to parts and products 
manufacturing. 



Then 



HH = GG x 0.01/0.42, 



(A-26) 



where HH = tool steel parts and products manu- 
facturing waste, 

and 0.01/0.42 = ratio of tool steel parts and products 
manufacturing waste to tool steels 
input to parts and products manu- 
facturing (1). 

Then II = GG - HH, (A-27) 

where II = tool steel parts and products. 

STAINLESS AND HEAT-RESISTANT STEELS 

AND OTHER ALLOYS (EXCLUDING ALLOY 

STEELS AND SUPERALLOYS) 

This industry consists of the production and processing 
of alloys and the manufacture of parts and products from 
the alloys. 



LL = JJ + KK, 



(A-28) 



where 



and 



JJ = stainless and heat-resistant primary 
cobalt input to this industry (19), 

KK = other alloys primary cobalt input to 
this industry (19), 

LL = total primary cobalt input to the in- 
dustry. 



15 



where 


MM 


and 


0.1/0.6 


Then 




where 


NN 


Then 




where 


PP 


and 


0.03/0.7 


Then 




where 


00 


and 


0.03/0.7 


Then 




where 


RR 


Then 




where 


SS 


and 


0.01/0.64 


Then 




where 


TT 


and 


0.1/0.64 



MM = LL x 0.1/0.6, (A-29) 

= prompt scrap input to this industry, 

= ratio of prompt scrap input to total 
primary cobalt input (i). 

NN = LL + MM, (A-30) 

= total cobalt input to these alloys. 

PP = NN x 0.03/0.7, (A-31) 

= metal processing waste, 

= ratio of metal processing waste to 
total input cobalt (i). 

QQ = NN x 0.03/0.7, (A-32) 

= metal processing downgraded scrap, 

= ratio of metalprocessing downgraded 
scrap to total input cobalt (i). 



RR = NN - PP - QQ, 



(A-33) 



= input metal to parts and products 
manufacturing. 



SS = RR x 0.01/0.64, 



(A-34) 



= parts and products manufacturing 
waste, 

= ratio of parts and product manufac- 
turing waste to input metal to parts 
and products manufacturing (i). 



TT = RR x 0.1/0.64, 



(A-35) 



= parts and products manufacturing 
downgraded scrap, 

= ratio of parts and products manufac- 
turing downgraded scrap to input 
metal to parts and products 
manufacturing (2). 



Then UU 

where UU 



= RR - SS - TT - MM, 
= parts and products. 



(A-36) 



MISCELLANEOUS AND UNSPECIFIED 

These industries are a collection of miscellaneous pro- 
cesses and products. It is assumed that each component 
has a metal processing phase and a parts and products 
phase. 

AAA = sum(W + WW + XX + 



YY + ZZ), 



(A-37) 



where AAA = total primary cobalt input to mis- 
cellaneous and unspecified metal 
processing, 

W = primary cobalt input to full alloy steel, 

WW = primary cobalt input to high-strength 
low-alloy steel, 

XX = primary cobalt input to nonferrous 
alloys, 

YY = primary cobalt input to welding mate- 
rials, 



and 



Then 



ZZ = primary cobalt input to other miscella- 
neous and unspecified uses. 



BBB = AAA x 1/6, 



(A-38) 



where BBB = prompt scrap input to miscellaneous 
and unspecified metal processing, 

and 1/6 = ratio of prompt scrap to primary cobalt 

input to miscellaneous and unspecified 
metal processing (7). 

Then CCC = (AAA + BBB) x 0.03/0.7, (A-39) 

where CCC = metal processing waste, 

and 0.03/0.7 = ratio of metal processing waste to total 
cobalt input to miscellaneous and un- 
specified metal processing (i). 

Then DDD = (AAA + BBB) x 0.03/0.7, (A-40) 

where DDD = metal processing downgraded scrap, 

and 0.03/0.7 = ratio of metal processing downgraded 
scrap to total cobalt input to mis- 
cellaneous and unspecified metal pro- 
cessing (i). 



16 



Then EEE = (AAA + BBB) - CCC - DDD, (A-41) 

where EEE = metal to miscellaneous and unspecified 
metal parts and products. 

Then FFF = EEE x 0.01/0.64, (A-42) 

where FFF = parts and products manufacturing waste, 

and 0.01/0.64 = ratio of parts and products manufac- 
turing waste to cobalt input to parts 
and products manufacturing. 



Then 



GGG = EEE x 0.1/0.64, 



(A-43) 



where GGG = parts and products manufacturing 
downgraded scrap, 

and 0.1/0.64 = ratio of parts and products manu- 
facturing downgraded scrap to input 
cobalt to parts and products manu- 
facturing (1). 

Then HHH = EEE - FFF - GGG - BBB, (A-44) 

where HHH = miscellaneous and unspecified parts and 
products. 

CATALYSTS 

Catalysts are produced in a two-phase operation. The 
first is processing to a metal form or alloy and the second 
the manufacturing of the catalysts themselves. 

JJJ = III x 0.05/1.7, (A-45) 

where JJJ = chemical production waste, 

III = primary cobalt input to chemical 
production, 

and 0.05/1.7 = ratio of chemical production waste to 
primary cobalt input to chemical 
production (1). 



Then 



KKK = III - JJJ, 



(A-46) 



where KKK = produced chemicals input to catalyst 
product manufacturing. 

Then LLL = KKK x 0.05/1.65, (A-47) 

where LLL = catalyst product manufacturing waste, 

and 0.05/1.65 = ratio of catalyst product manufacturing 
to produced chemicals input to catalyst 
product manufacturing (1). 



Then MMM = KKK - LLL, (A-48) 

where MMM = catalyst products. 

OTHER CHEMICALS 

This industry produces paint driers, feed and nutritive 
additives, glass decolorizers, ground coat frit, and pig- 
ments. Each product was assumed to be produced by a 
two-phase operation. The first phase is chemical produc- 
tion and the second product manufacturing. 

NNN = sum(PPP + QQQ + RRR + 

SSS + TTT) x 0.03, (A-49) 

where NNN = chemical production waste, 

PPP = primary cobalt input to paint driers (19), 

QQQ = primary cobalt input to feed and 
nutritive additives (19), 

RRR = primary cobalt input to glass decolor- 
izers (19), 

SSS = primary cobalt input to ground coat 
frit (19), 

TTT = primary cobalt input to pigments (19), 

and 0.03 = chemical production waste based on 

97-pct efficiency in chemical produc- 
tion (7). 

Then UUU = sum(PPP + QQQ + RRR + 

SSS + TTT) - NNN, (A-50) 

where UUU = produced chemicals input to chemical 
product manufacturing. 

Then VW = UUU x 0.05, (A-51) 

where VW = chemical product manufacturing waste, 

and 0.05 = waste loss based on 95-pct efficiency 

in chemical product manufacturing 
(5-pct waste loss) (1). 



Then WWW = UUU - VW, 

where WWW = chemical products. 



(A-52) 



INT.BU.OF MINES,PGH.,PA 29148 



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